Finite Element Analysis on Segmented Chip Formation for High Speed Cutting of Ti6Al4V Alloy

2009 ◽  
Vol 407-408 ◽  
pp. 599-603
Author(s):  
Xiang Hua Zhang ◽  
Hong Bing Wu
Keyword(s):  
Finite Element ◽  
Titanium Alloy ◽  
Finite Element Model ◽  
Chip Formation ◽  
High Speed ◽  
Element Model ◽  
High Speed Cutting ◽  
Segmented Chip ◽  
Titanium Alloy Ti6al4v ◽  
The Finite Element Model

To accurately simulate the segmented chip formation of titanium alloy Ti6Al4V in high speed cutting process, the key techniques of the finite element modeling were investigated detailed, which included establishing the finite element model, material constitutive relation, chip separation criteria, material failure criteria. A high speed cutting case of titanium alloy Ti6Al4V were simulated with thermal mechanical analysis and adiabatic analysis respectively. Through the comparison of the two simulated results, it proved the segmented chip is formed because of the adiabatic shear. The results prove the finite element model established is correct.

Mechanics Model and Finite Element Simulation of High Speed Orthogonal Cutting of Titanium Alloy

2010 ◽  
Vol 139-141 ◽  
pp. 1101-1104
Author(s):  
Yong Yang ◽  
Yu Ling Wang ◽  
Chang He Li
Keyword(s):  
Finite Element ◽  
Titanium Alloy ◽  
Finite Element Model ◽  
Finite Element Simulation ◽  
High Speed ◽  
Orthogonal Cutting ◽  
Element Model ◽  
Simulation Accuracy ◽  
Element Simulation ◽  
Titanium Alloy Ti6al4v

Though a lot of research works have been done, some key technologies of finite element simulation have not been resolved completely. A detailed finite element model of high speed orthogonal cutting of titanium alloy Ti6Al4V is developed. Several mechanics models of cutting process, such as material constitutive model, chip separation model and chip damage model, are implemented to improve finite element simulation accuracy. The chip shape and cutting force agree well with experimental results, which show the finite element model developed in this study is reasonable. Using this finite element model, chip formation process of titanium alloy Ti6Al4V is simulated. Results indicate that the material between the shear bands is only weakly deformed, and the deformation is stronger on the tool side of the chip. This work will be a base for process parameter optimization, tool’s optimization selection and design during high speed cutting of difficult-to-cut titanium alloy.

Finite Element Investigation of the Influence of Thermophysical Parameters on Segmented Chip Formation during High Speed Cutting

2011 ◽  
Vol 130-134 ◽  
pp. 2817-2821
Author(s):  
You Xi Lin ◽  
Cong Ming Yan
Keyword(s):  
Thermal Conductivity ◽  
Finite Element ◽  
Specific Heat ◽  
Chip Formation ◽  
High Speed ◽  
Element Model ◽  
Serrated Chip ◽  
High Speed Cutting ◽  
Thermophysical Parameters ◽  
Serrated Chip Formation

A 2D fully thermal mechanical coupled finite element model is applied to study the influence of material parameters on serrate chip formation during high speed cutting process. The serrated chip formation during high speed machining was predicted. Of interests are the effects of thermal conductivity, specific heat and density. Results showed significant influence of these thermophysical parameters on the serrated chip phenomena, especially in the case of the density. Increasing thermal conductivity specific heat and density lead to a decreasing degree of segmentation. The influence of the thermal conductivity on the cutting force and the specific heat on maximum temperatures in the shear band is also discussed.

Modal Analysis of BT Spindle-Toolholder Interface Based on Abaqus/Standard

2013 ◽  
Vol 662 ◽  
pp. 632-636
Author(s):  
Yong Sheng Zhao ◽  
Jing Yang ◽  
Xiao Lei Song ◽  
Zi Jun Qi
Keyword(s):  
Finite Element ◽  
Finite Element Model ◽  
Modal Analysis ◽  
Dynamic Characteristics ◽  
High Speed ◽  
Element Model ◽  
Contact Theory ◽  
High Speed Machining ◽  
The Finite Element Model

The quality of high speed machining is directly related to dynamic characteristics of spindle-toolholder interface. The paper established normal and tangential interactions of BT spindle-toolholder interface based on finite element contact theory, and analysed free modal in Abaqus/Standard. Then the result was compared with the experimental modal analysis. It shows that the finite element model is effective and could be applied in the future dynamic study of high-speed spindle system.

scholarly journals Experiment and Analysis of Cord Stress on High-Speed Radial Tire Standing Waves

2019 ◽  
Vol 2019 ◽  
pp. 1-9
Author(s):  
Peng-Fei Sun ◽  
Hong-Wu Huang ◽  
Shui-Ting Zhou ◽  
Yi-Jui Chiu ◽  
Meng Du ◽  
...  
Keyword(s):  
Finite Element ◽  
Finite Element Model ◽  
High Speed ◽  
Standing Waves ◽  
Element Model ◽  
Experimental Results ◽  
Radial Tire ◽  
Oblique Wave ◽  
Vehicle Velocity ◽  
The Finite Element Model

This paper elaborates on the production mechanisms of standing waves during high-speed tire rolling and analyzes the relationship between the change of wavelength of sidewall waves and the vehicle velocity, from an oblique wave point of view. A finite element model for a 195/65R15 radial tire is established with the nonlinear analysis software ABAQUS, based on the tire structure and cord parameters. This paper comparatively analyzes the finite element simulation results and experimental results of the tire load-sinkage relation and the load vs inflatable section width relation and finds little difference between the simulation and experimental results. A similar analysis studies the change in the wavelength of sidewall standing waves at different vehicle velocities during high-speed tire rolling. The calculated value by the oblique wave approach, the value by simulation, and the experimental results demonstrate high consistency, concluding that during high-speed tire rolling, the wavelength of sidewall standing waves increases with vehicle velocity. Thus, the accuracy of the finite element model is verified under both static and dynamic conditions. Under a constant tire pressure and load, the impact of velocity change on tire-cord stress during high-speed tire rolling is studied based on the finite element model so as to identity the relation between the cord stress and standing waves.

A Hybrid 2.5D High Speed Strip Theory Method and its Application to Apply Pressure Loads to 3D Full Ship Finite Element Models

2014 ◽  
Author(s):  
Chengbi Zhao ◽  
Ming Ma
Keyword(s):  
Finite Element ◽  
Finite Element Model ◽  
High Speed ◽  
Hybrid Approach ◽  
Structural Models ◽  
Element Model ◽  
3D Finite Element ◽  
Hull Girder ◽  
Strip Theory ◽  
The Finite Element Model

As the three-dimensional finite element model has become the de facto standard for ship structural design, interest in accurately transferring seakeeping loads to panel based structural models has increased dramatically in recent years. In today’s design practices, panel based hydrodynamic analyses are often used for mapping seakeeping loads to 3D FEM structural models. However, 3D panel based hydrodynamic analyses are computationally expensive. For monohull ships, methods based on strip theories have been successfully used in the industry for many years. They are computationally efficient, and provide good predictions for motions and hull girder loads. However, many strip theory methods provide only hull girder sectional forces and moments, such as vertical bending moment and vertical shear force, which are difficult to apply to 3D finite element structural models. Previously, the authors have proposed a hybrid strip theory method to transfer 2D strip theory based seakeeping loads to 3D finite element models. In the hybrid approach, the velocity potentials of strip sections are first calculated based on the ordinary 2D strip theories. The velocity potentials of a finite element panel are obtained from the interpolation of the velocity potentials of the strip sections. The panel pressures are then computed based on Bernoulli’s equation. Integration of the pressure over the finite element model wetted panels yields the hydrodynamic forces and moments. The equations of motion are then formulated based on the finite element model. The method not only produces excellent ship motion results, but also results in a perfectly balanced structural model. In this paper, the hybrid approach is extended to the 2.5D high speed strip theory. The simple Rankine source function is used to compute velocity potentials. The original linearized free surface condition, where the forward speed term is not ignored, is used to formulate boundary integral equations. A model based on the Series-64 hull form was used for validating the proposed hybrid method. The motion RAOs are in good agreement with VERES’s 2.5D strip theory and with experimental results. Finally, an example is provided for transferring seakeeping loads obtained by the 2.5D hybrid strip theory to a 3D finite element model.

Mechanics Modeling and Three-Dimensional Finite Element Simulating for High Speed Milling of Titanium Alloy

2010 ◽  
Vol 29-32 ◽  
pp. 360-364
Author(s):  
Yong Yang ◽  
Yu Ling Wang ◽  
Chang He Li
Keyword(s):  
Finite Element ◽  
Titanium Alloy ◽  
Finite Element Model ◽  
High Speed ◽  
Three Dimensional ◽  
Element Model ◽  
Milling Process ◽  
High Speed Milling ◽  
Dimensional Finite Element ◽  
Three Dimensional Finite Element

A three-dimensional finite element model of helix double-edge cutting is developed to study the ending milling process of titanium alloy Ti6Al4V. Several mechanics models of milling process, such as material constitutive model, friction model and heat transfer model, are implemented to improve finite element simulating accuracy. A milling force experiment is carried out, and a good agreement between simulation and experimental value is achieved, which proved that the finite element model presented in this paper is correct. Using this finite element model, chip formation and cutting temperature are simulated and analyzed. This work will be a base for process parameter optimization, tool’s optimization selection and design during high speed milling of difficult-to-cut titanium alloy.

Optical Microscopy-Aided Indentation Tests

2008 ◽  
Vol 130 (1) ◽  
Author(s):  
D. A. Doman ◽  
R. Bauer ◽  
A. Warkentin
Keyword(s):  
Finite Element ◽  
Finite Element Model ◽  
Optical Microscopy ◽  
High Speed ◽  
Material Model ◽  
Element Model ◽  
Rolling Contact ◽  
Analytical Models ◽  
Indentation Tests ◽  
The Finite Element Model

The contact characteristics of ceramic-metallic interactions are of critical importance in the design of high-speed ceramic rolling contact bearings. This type of interaction is not described well by traditional indentation tests since small displacements and barely discernable indentations are encountered. In this work, an optical microscopy system is described that is used to measure small indenter displacements accurately. Images of the indenter are taken throughout the test and processed using sophisticated edge detection algorithms to accurately determine the position of the center of the indenter. Thus, the indenter displacements on the order of 1μm can be measured independent of any structural flexibility present in the test apparatus. Experimental indentation tests using an alumina indenter mounted on a stainless steel post were performed and processed with the optical system. The results were compared to existing analytical models for fully elastic and elastoplastic cases as well as a finite element model developed using a Johnson–Cook plasticity material model. The comparison shows that the analytical models do not predict the experimental results well, whereas the finite element model agrees very well. Subsequent analysis of the finite element model shows that the size of the contact zone and pressure distributions, both very important in the design of bearings, can be more accurately described than the traditional analytical treatments.

scholarly journals Damage Identification of High-speed Maglev Guideway Girder Based on Modal Identification

2021 ◽  
Keyword(s):  
Finite Element ◽  
Finite Element Model ◽  
Health Monitoring ◽  
High Speed ◽  
Damage Identification ◽  
Element Model ◽  
High Tech ◽  
Maglev Train ◽  
Identification Method ◽  
The Finite Element Model

Abstract. As a modern high-tech rail vehicle, the maglev train realizes the non-contact suspension and guidance between the train and the guideway, which greatly reduces the resistance of the system. Due to the high-speed operation characteristics of maglev trains, the structural health monitoring of guideway girders is particularly important for the safety and stability of maglev train operation. This paper takes the maglev train guideway girder as the monitoring target, and the finite element model of the maglev vehicle-guideway is established to simulate the running state of the train passing through the guideway girder. The dynamic response data of the guideway girder is obtained in the finite element model, considering healthy states and different damage states of the guideway girder. Then, a modal-based damage identification method is proposed, which obtains the guideway girder damage sensitive characteristics by decomposing the guideway girder acceleration response signal. Finally, based on the measured guideway girder acceleration data, this paper verifies the effectiveness of the damage identification method in guideway girder structure health monitoring, which provides reference and guidance for the future maintenance of the maglev guideway girder.

Non-Linear FEA of AA 5083 Welded Joints for High-Speed Marine Vehicles

2020 ◽  
Author(s):  
Pasqualino Corigliano ◽  
Vincenzo Crupi
Keyword(s):  
Finite Element ◽  
Finite Element Model ◽  
Welded Joints ◽  
High Speed ◽  
Element Model ◽  
Plastic Behavior ◽  
Full Field ◽  
Marine Vehicles ◽  
Non Linear ◽  
The Finite Element Model

The AA 5083 aluminium alloy is widely used in high speed marine vehicles. The aim of this scientific work was to develop and validate a procedure, starting only from hardness measurements, to predict the elastic-plastic behavior of AA 5083 welded joints under static loading using non-linear FEA analyses. The hardness measurements allowed identifying the different zones and to assess their different mechanical properties, which were considered in the finite element model. Finally, the finite element model results were validated experimentally, comparing the results with the measurements obtained by means of a full-field technique such as the Digital Image Correlation technique.

Finite Element Simulation of High-Speed Cutting Alloy Cast Iron

2006 ◽  
Vol 532-533 ◽  
pp. 749-752 ◽  
Author(s):  
Jing Kui Ruan ◽  
Ying Lin Ke ◽  
Hui Yue Dong ◽  
Yong Yang
Keyword(s):  
Finite Element ◽  
Cast Iron ◽  
Finite Element Model ◽  
High Speed ◽  
High Strain ◽  
Cutting Temperature ◽  
Element Model ◽  
High Speed Cutting ◽  
Alloy Cast Iron ◽  
Alloy Cast

A finite element model (FEM) of high-speed cutting was built to study the mechanism of high-speed machining of alloy cast iron used widely in auto panel dies. The mechanics properties of workpiece material were obtained in the conditions of high strain-rate, high temperature and high strain through high-speed impact compress experiments. Several key technologies are studied such as friction and chip-tool heat conduction. The cutting temperature, stress distribution, and the chip formation process in the process of high-speed cutting alloy cast iron were analyzed based on the finite element model, which was validated through cutting force experiments. It shows that the FEM can simulate the high-speed cutting process of alloy cast iron materials.

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